Funded by the Technology Strategy Board (TSB) and undertaken in conjunction with Rolls-Royce, Nottingham University and Birmingham University, Wilde Analysis has developed a user-friendly software tool allowing non-simulation specialists to undertake simulations of the manufacture of disks and shafts for turbines. Future efficient lightweight aero-engines will rely on the next generation of high temperature materials. However, they present new manufacturing challenges, particularly in joining where friction welding has been identified as a key enabling technology. Sponsored by the TSB, the Process Modelling for Tomorrow’s Engines (PROMOTE) project is a collaborative project involving Rolls-Royce, Wilde Analysis and the Universities of Nottingham and Birmingham, which was tasked with capturing the state-of-the-art in materials and process modelling and implementing it in an end user-focused software tool. General details on the project were published in an article in Eureka Magazine (http://www.eurekamagazine.co.uk/article/22229/Process-modelling-improves-aero-engine-design.aspx) in 2010. This overview presentation has been made at conferences. Please contact us at http://WildeAnalysis.co.uk/contact for more information on: - The PROMOTE software and options to use it for your processes - DEFORM process modelling software and consulting services - Our software customisation services

1. improving design by analysis
The PROMOTE Software
James Farrar
Business Development Manager

2. Wilde Overview
• Formed in 1980 as Finite Elements Ltd
• 1000+ clients
• Member of Wilde Group of 70+ employees and £10m +
turnover
• 24 employees involved in analysis sales, services and
administration
– 21 are qualified engineers with significant experience using analysis
software
• ISO 9001:2008 Approved Quality Management System
• On UK-steering committee for NAFEMS and
involvement with many industry associations.

3. DEFORM SYSTEM
raw material production forming heat treatment &
microstructure
Installation / in- machining distortion machining
service performance & residual stress

4. DEFORM Business
• Wilde - UK Distributor for 15 years
• UK, Ireland, Northern Europe, France
• Software
• Training
• Technical support
• Consulting services

5. PROMOTE Brief Overview
• Manufacturing route for turbine discs and
shafts is well defined. Post Solution HT Quench
• Improved engine performance requires
optimisation of the manufacturing process
Ageing Heat Treatment
routes in each area.
• Aim of PROMOTE is to deliver a software tool
to model all of the processes involved in the Machining Operations
manufacture of aerospace disc and shaft
assemblies Inertia Welding
Machining Operations
Post Welding Heat
Treatment

6. PROMOTE Interface Objective
• Deliver capability for modelling disc and shaft manufacturing routes.
• Provide process modelling capability to process and materials specialists rather
than a very small population of process modelling specialists.
• Deliver a user-friendly software environment to enable use of the modelling
capability in a quality controlled and efficient manner.
• Without the need for extensive training or specialist background knowledge in
process modelling.
• Enable users to input the required process parameters and automatically
convert this information to DEFORM requirements.
• Capture current state-of-art for current process modelling.
Single user-friendly interface
Initial Process Model Process Model
Geometry Parameters Results Parameters Results
Material Material
Properties Properties
Initial Material Process Modified Process Modified
etc.
Properties Model Geometry Model Geometry
Residual Residual
Stress Stress

7. PROMOTE Development
• WP1: Rolls Royce
• Material acquisition, characterisation, modelling and test sample
manufacturing (University of Birmingham)
• WP2: Rolls Royce - Manufacturing Process Modelling
• Heat Treatment
• Machining (Distortion)
• Inertia Welding (University of Nottingham)
• WP3: Wilde Analysis
• PROMOTE Software integration and system development

8. PROMOTE - Basic Concepts
• Object-oriented paradigm:
– “Workpiece” object Label identifies
Label
workpiece ID and
its current state
– “Process” object Process
– Process changes state of workpiece
New
label

9. Basic Concepts – ctd
• Representation of manufacturing route
Fore 1a 2a Aft
Age Quench
1b 2b
Time
Machine
1c
Weld
Note: new workpiece 12a
’12’ with initial state ‘a’

10. Basic Concepts – ctd
• Define manufacturing route
• Define “process” object attributes
– Process parameters, jigs & fixtures, etc
• Define initial “workpiece” object attributes
– geometry, material, etc
• Subsequent object attributes determined by
preceding processes

11. Basic Mechanics
• Process simulation in text-driven DEFORM
Keyword Text file(s) containing info on
file(s) workpiece, material, process
parameters and numerics
Instruction(s): ‘read file’
Pre-processor
Instruction: ‘generate database’
Text file containing complete Database Binary file containing
description of workpiece state file complete problem description
Instruction: ‘run solver’
Solver
Instruction: ‘write
Keyword keyword file for Database
file workpiece’ file

12. PROMOTE Workflow
Workpiece data entry
Engine
assembly display
Import / specify
workpiece
Geometry
Material
Mesh
Geometry
display

13. PROMOTE Interface
Age process data entry
ble
ses
Engine
assembly display
Material
model inputs
User defined microstructure models
User defined microstructure models MSRR file input
Process
inputs
Customised, automated model inputs
Customised, automated model inputs
Points for
auto – post
T ( C) T ( C)
processing
Geometry
display
try
Geometry t(s)
display t(s)
Temperature profile input

14. PROMOTE Interface
Weld process inputs
Engine
assembly display
Material
model inputs
Dies &
Fixtures
Weld inputs
(Load /
inetrtia)

15. PROMOTE Interface
Machine process inputs
Engine
assembly display
Cut profiles

16. PROMOTE Interface
Machine process inputs
Engine
assembly display
Cut profiles

17. PROMOTE Interface
Automated batch
run scheduling
Automated & interactive
post –processing options

18. The Way Forward
• Background information on DEFORM:
www.wildeanalysis.co.uk
www.deform.com
• Contact James Farrar to:
– Discuss your simulation requirements
– Arrange a company-specific web or live meeting on the
PROMOTE and DEFORM software
– Discuss evaluation options
jfarrar@wildeanalysis.co.uk Tel: 0161 4747479